Multi-Purpose Gas Separator Unit and Associated Methods

ABSTRACT

Inlet and outlet connections of a well manifold connect to integrated piping of a unitary vessel on a skid. The unitary vessel defines an interior separated into two chambers by a barrier. One chamber has a test inlet for well testing operation, and the other chamber has a production inlet for production operation. Each of the chambers is in communication with a gas outlet for gas, a water outlet for water, and a condensate outlet for condensate. Each of the chambers has a weir plate disposed in the chamber and separating the water outlet on a waterside of the weir plate from the condensate outlet on a condensate-side of the weir plate adjacent the barrier. During use, the second chamber can be isolated so well testing operation can be performed using the first chamber. Also, the first chamber can be isolated so production operation can be performed using the second chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.15/442,026, filed 24 Feb. 2017, which claims the benefit of U.S. Prov.Appl. 62/299,536, filed 24 Feb. 2016, both of which are incorporatedherein by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

During well operations, it is desirable at times to measure gasconcentrations and the like. Typically, a gas separator is used for thispurpose. Oil and water separation is necessary to make the measurements,and condensate needs to be separated so gas can be collected. To thatend, wellsite installations use a production gas separator to measuregases during production of a well.

Measuring gas concentrations during well testing, however, is differentfrom production operations. Conventionally, an individual vessel is usedfor production separation, while another individual vessel is used forseparation to perform the well testing. When well testing and productionare to be performed, the use of such individual vessels increases costs,complicates the configuration of the wellsite, and causes otherrecognizable problems.

The subject matter of the present disclosure is directed to overcoming,or at least reducing the effects of, one or more of the problems setforth above.

SUMMARY OF THE DISCLOSURE

A multi-purpose gas separator unit includes a unitary vessel defining aninterior. The vessel has a test inlet at a first end and has aproduction inlet at a second, opposite end. A barrier disposed in theinterior seals the interior into first and second chambers. The firstchamber communicates with the test inlet and is adapted for well testingoperation, while the second chamber communicates with the productioninlet and is adapted for production operation. The first chamber is incommunication with a first gas outlet of the vessel for gases, and thesecond chamber in communication with a second gas outlet of the vesselfor gases.

A barrier disposed in the interior seals the interior into first andsecond chambers. The first chamber communicating with the test inlet isadapted for well testing operation, while the second chambercommunicating with the production inlet is adapted for productionoperation. Each of the chambers is in communication with a gas outlet ofthe vessel for gas, a water outlet of the vessel for water, and acondensate outlet of the vessel for condensate. A first weir plate isdisposed in the first chamber, and a second weir plate is disposed inthe second chamber. Each of the weir plates separate the water outlet ona waterside of the weir plate from the condensate outlet on acondensate-side of the weir plate adjacent the barrier.

The disclosed unit can include an equalizing valve in communicationbetween the first and second chambers of the vessel. The equalizingvalve is operable to equalize the first and second chambers across thebarrier. The first and second chambers can be equalized across thebarrier based on a pressure differential between the inlets and outletsfor the two chambers.

The barrier can include a plate welded in the interior of the vessel toseal the first and second chambers from one another.

For the first chamber adapted for testing, the disclosed unit includes alevel gage for measuring an interface between water and oil on thewaterside of the first weir plate and includes another level gage formeasuring condensate on the condensate-side of the first weir plate. Forthe second chamber adapted for production, the disclosed unit includes alevel gage for measuring an interface between water and oil on thewaterside of the second weir plate and includes another level gage formeasuring condensate on the condensate-side of the second weir plate.

A first volume of the first chamber can be less than a second volume ofthe second chamber. However, the volumes on the condensate sides of thefirst and second weir plates can be roughly the same. A reliefarrangement can communicate the first and second chambers to a vent.

In use, inlet and outlet connections of a well manifold connect tointegrated piping of the unitary vessel on a skid. In one set up, thesecond chamber can be isolated so well testing operation can beperformed using the first chamber. In another set up, the first chambercan be isolated so production operation can be performed using thesecond chamber.

The foregoing summary is not intended to summarize each potentialembodiment or every aspect of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic of a multi-purpose gas separator unitaccording to the present disclosure.

FIGS. 2A-2B illustrate isometric views of an embodiment of a first endof the disclosed unit showing the nozzle schedule and variouscomponents.

FIGS. 3A-3B illustrate isometric views of a second end of the disclosedunit showing the nozzle schedule and various components.

FIGS. 4A-4B illustrate upper plan views of the disclosed unit revealingplacement of various components.

FIGS. 5A-5B illustrate elevational views of opposing sides of thedisclosed unit.

DETAILED DESCRIPTION OF THE DISCLOSURE

FIG. 1 illustrates a schematic of a multi-purpose gas separator unit 10according to the present disclosure. The unit 10 includes a unitary orsole pressure vessel 20 used for both well testing and productionoperations. The vessel 20 includes an interior 21 and can be of standardconstruction. Internally, the vessel 20 includes a seal plate 26dividing the interior 21 into a test chamber 22A and a productionchamber 22B. Each chamber 22A-B includes a weir plate 28A-B disposed inthe vessel's interior 21 so that each chamber 22A-B acts as a 3-phaseseparator. Each chamber 22A-B can also include a temperature gage, apressure gage, and other comparable components as labelled.

With more particularity, a test inlet 24A from a test header 25A entersat the top of the test chamber 22A, and a production inlet 24B from aproduction header 25B enters at the top of the production chamber 22B atthe opposing end of the vessel 20. Between the two chambers 22A-B, thevessel 20 includes an equalizing line with a valve 30, which can be usedfor equalizing the two sides of the vessel 20 across the seal plate 26.

To measure the interface level between water and oil in the test chamber22A, the unit 10 has a level gage 32A, along with appropriate levelcontrols, valves, and piping to the chamber 22A, disposed on thewater-side of the weir plate 28A. To measure the level of condensate inthe test chamber 22A, the unit 10 has another level gage 34A, along withappropriate level controls, valves, and piping to the test chamber 22A,disposed on the condensate-side of the weir plate 28A.

In general and as shown, the water level gage 32A can include a magneticlevel gage having a low level switch and a level controller. The levelcontroller can be in operable communication with a level valve 33A influid communication with the water outlet 27A of the test chamber 22A.For its part, the condensate level gage 33A can include a magnetic levelgage having a high level switch, a low level switch, and a levelcontroller. This level controller can be in operable communication witha level valve 35A in fluid communication with the condensate outlet 29Aof the test chamber 22A.

To output produced water from the test chamber 22A, a first outlet 27Aconnects with appropriate piping, produced water level valve 33A, andthe like to a water outlet 48 of the unit 10. A flow sensor 27′ andtransmitter are in operable communication with the water outlet 27A ofthe test chamber 22A to measure the output of produced water.

To output the condensate from the test chamber 22A, a second outlet 29Aconnects with appropriate piping, produced condensate level valve 33A,and the like to a condensate outlet 46 of the unit 10. A flow sensor 29′and transmitter are in operable communication with the condensate outlet29A of the test chamber 22A to measure the output of condensate.

Gases from the test chamber 22A can exit via venting 40A (shown on thewaterside of the weir plate 28A) through piping, pressure safety valves,pressure gages, and the like to a vent stack or flare 42. Meanwhile,gases from the test chamber 22A can exit via a chamber outlet 43A (shownon the condensate side of the weir plate 28A) through piping, pressurevalves, pressure controls, and the like to a gas outlet 44. A filterarrangement (not labeled) can communicate between outlet 43A of thechamber 22A to the piping leading to the gas outlet 44. A flow sensor 45and transmitter are in operable communication between the chamber outlet43A and the gas outlet 44 of the test chamber 22A.

The production side of the unit 10 is comparably arranged. As alreadynoted, the production inlet 24B from the production header 25B enters atthe top of the production chamber 22B at the waterside of the weir plate28B. To measure the interface level between water and oil in theproduction chamber 22B, the unit 10 has a level gage 32B, along withappropriate level controls, valves, and piping to the chamber 22B,disposed on the waterside of the weir plate 28B. To measure the level ofcondensate in the production chamber 22B, the unit 10 has another levelgage 34B, along with appropriate level controls, valves, and piping tothe production chamber 22B, disposed on the condensate-side of the weirplate 28B.

To output produced water from the production chamber 22B, a first outlet27B connects with appropriate piping, produced water level valve 33B,and the like to a water outlet 48 of the unit 10. To output thecondensate from the production chamber 22B, a second outlet 29B connectswith appropriate piping, produced condensate level valve 33B, and thelike to a condensate outlet 46 of the unit 10.

Finally, gases from the production chamber 22B can exit via venting 40B(shown on the waterside of the weir plate 28B) through piping, pressuresafety valves, pressure gages, and the like to a vent stack or flare 42.Meanwhile, gases from the production chamber 22B can exit via a chamberoutlet 43B (shown on the condensate side of the weir plate 28B) throughpiping, pressure valves, pressure controls, and the like to a gas outlet44. Again, a filter arrangement (not labeled) can communicate betweenthe chamber outlet 43B to the piping leading to the gas outlet 44.

With an understanding of the schematic arrangement of the disclosedmulti-purpose separator unit 10, discussion now turns to a particularconfiguration of the disclosed unit 20. In particular, FIGS. 2A-2Billustrate isometric views of a first end of an embodiment of thedisclosed unit 10 showing the nozzle schedule and various componentsarranged relative to the unitary vessel 20. FIGS. 3A-3B illustrateisometric views of a second end of the disclosed unit 10.

As can be seen, the unit 10 includes a skid 12 with a surrounding frame14 that supports the unitary vessel 20. The various piping, valves,gages, and other integrated components of the unit 10 mount about thevessel 20 in the profile of the skid 12 and the frame 14 to provide asmall footprint for the unit 10. The control interface 50 for the unit10 is accessible on the frame 14.

The nozzle connections for the unit 10 include a test inlet A, aproduction inlet B, a condensate outlet C, a produced water outlet D, agas outlet E, and a relief outlet F. The test and production inlets A-Benter the top of the vessel 20 from the upper side of the skid 12 andframe 14. Advantageously, the outlets C, D, E, and F extend from one endof the skid 12 and the frame 14 to facilitate incorporating thedisclosed unit 10 into the surrounding processes and piping, including amanifold 70 at the wellsite.

FIGS. 4A-4B illustrate the arrangement of components of the unit 10 onthe skid 12 and the frame 14 in more detail. In particular, FIG. 4Ashows an upper plan view of the disclosed unit 10 revealing placement ofvarious components. FIG. 4B shows the upper plan view with elementsremoved to reveal the configuration of components relative to the vessel20. Meanwhile, FIGS. 5A-5B illustrate elevational views of opposingsides of the disclosed unit 10.

As best shown in the plan view of FIG. 4B, the vessel 20 can be dividedinto the two chambers 22A-B to provide different volumes. As expected,the volume of the test chamber 22A can be less than that of theproduction chamber 22B. Therefore, the seal plate 26 in the interior 21can be offset toward one end of the vessel 20. Placement of the inletsand outlets on the vessel 20 for the test chamber 22A are shown relativeto the weir plate 28A and include a port for the water/oil interfacelevel gage, a port for the produced water outlet, a port of thecondensate water outlet, and a port for the condensate level gage.Likewise, placement of the inlets and outlets on the vessel 20 for thelarger production chamber 22B is shown relative to the weir plate 28Band include a port for the production section level gage, a port for theproduced water outlet, a port for the condensate water outlet, and aport for the condensate level gage. As depicted, the condensing volumesof the chambers 22A-22B on the condensate sides of the weir plates 28A-Bmay be comparable to one another, whereas the volume of the chambers22A-B on the watersides of the weir plates 28A-B can be different.

The multi-purpose separator unit 10 is a separator vessel with aninternal seal plate 26 dividing the vessel's interior into dual, 3-phaseseparators-one for testing and another for production. Accordingly, thevessel 20 with this seal plate 26 allows for simultaneous well testingand production. This dual capability makes the disclosed separator unit10 unique to all other separator configurations that consist of anindividual vessel for production separation and another individualvessel for separation to perform well testing. The seal plate 26 ispositioned for a single well test while the remaining portion of thevessel 20 is dedicated to conventional separation to accommodate thebasis of design.

The multi-purpose separator unit 10 can be pressure balanced by theproduction manifold 70 or by the vessel equalizing valve 30 installedupstream and downstream of the seal plate 26. In essence then, thedisclosed separator unit 10 offers one vessel serving two purposes,which is achievable with the pressure-balanced internal seal plate 26between the test and production chambers 22A-B.

Operations initially entail isolating the production section (e.g.,chamber 22B, etc.) from the test section (e.g., chamber 22A, etc.). Welltesting can begin at that point. Then, operations involve switching viathe manifold 70 to the production section while opening the necessaryisolation valves.

Instrumentation and controls for the multi-purpose separator unit 10 canbe comparable to those used for a typical independent test separator anda typical independent production separator. Of course, the dual controlsfor the disclosed separator unit 10 can be integrated together in theseparator's unitary control unit 60 to achieve both testing andproduction operations.

Because the multi-purpose separator unit 10 includes the dualfunctionality, the disclosed unit 10 can take up less deck spaceoffshore. Naturally, the overall weight of the disclosed separator unit10 can be more manageable, and any civil or structural foundations forsupporting the unit can be less costly.

The foregoing description of preferred and other embodiments is notintended to limit or restrict the scope or applicability of theinventive concepts conceived of by the Applicants. It will beappreciated with the benefit of the present disclosure that featuresdescribed above in accordance with any embodiment or aspect of thedisclosed subject matter can be utilized, either alone or incombination, with any other described feature, in any other embodimentor aspect of the disclosed subject matter.

As will be appreciated, various details related to dimensions, pressureratings, types of valves, etc. have been omitted as being understood bythe standard practices of one skilled in the art. Suffice it to say thatthe disclosed unit 10 can be properly configured to meet therequirements of a given implementation in accordance with such standardpractices without departing from the teachings of the presentdisclosure.

In exchange for disclosing the inventive concepts contained herein, theApplicants desire all patent rights afforded by the appended claims.Therefore, it is intended that the appended claims include allmodifications and alterations to the full extent that they come withinthe scope of the following claims or the equivalents thereof.

What is claimed is:
 1. A method for use with a manifold having inlet andoutlet connections, the method comprising: connecting the inletconnections of the manifold to integrated piping of a unitary vessel,the unitary vessel having an interior sealed into first and secondchambers by a barrier disposed in the interior, the first chamber incommunication with a first inlet, the second chamber in communicationwith a second inlet; connecting the outlet connections of the manifoldto the integrated piping of the unitary vessel, each of the first andsecond chambers in communication with a respective gas outlet for gas, arespective water outlet for water, and a respective condensate outletfor condensate, each of the first and second chambers having arespective weir plate disposed therein and separating the respectivewater outlet on a waterside of the respective weir plate from therespective condensate outlet on a condensate-side of the respective weirplate; and isolating the second chamber and performing a first operationusing the first chamber.
 2. The method of claim 1, wherein performingthe first operation using the first chamber comprises: measuring thewater of the first chamber and controlling output of the water from therespective water outlet of the first chamber; measuring the condensateof the first chamber and controlling output of the condensate from therespective condensate outlet of the first chamber; and measuring the gasof the first chamber and controlling output of the gas from therespective gas outlet of the first chamber.
 3. The method of claim 1,further comprising isolating the first chamber and performing a secondoperation using the second chamber.
 4. The method of claim 3, whereinperforming the first operation using the first chamber comprisesperforming a well testing operation using the first chamber; and whereinperforming the second operation using the second chamber comprisesperforming a production operation using the second chamber.
 5. Themethod of claim 4, further comprising integrating dual controls of theunitary vessel for both of the well testing and production operationswith a unitary control unit.
 6. The method of claim 4, whereinperforming the well testing operation using the first chamber comprisesusing the first chamber defining a first volume; and wherein performingthe production operation comprises using the second chamber defining asecond volume, the first volume being less than the second volume. 7.The method of claim 6, wherein performing the well testing operationusing the first chamber comprises using a first volume portion of thefirst volume on the condensate-side of the respective weir plate; andwherein performing the production operation comprises using a secondvolume portion of the second volume on the condensate-side of therespective weir plate, the second volume portion equivalent to the firstvolume portion.
 8. The method of claim 1, wherein performing the firstoperation using the first chamber comprises: measuring, with a firstlevel gage, a first interface between the water and oil on the watersideof the respective weir plate; and measuring, with a second level gage,the condensate on the condensate-side of the respective weir plate. 9.The method of claim 8, wherein measuring with the first level gagecomprises measuring with a first magnetic level gage having a first lowlevel switch and a first level controller; and wherein performing thefirst operation comprises controlling a first level of the water withthe first level controller in operable communication with a first levelvalve in fluid communication with the respective water outlet of thefirst chamber; and wherein measuring with the second level gagecomprises a second magnetic level gage having a high level switch, asecond low level switch, and a second level controller; and whereinperforming the first operation comprises controlling a second level ofthe condensate with the second level controller in operablecommunication with a second level valve in fluid communication with therespective condensate outlet of the first chamber.
 10. The apparatus ofclaim 8, further comprising isolating the first chamber and performing asecond operation using the second chamber, wherein performing the secondoperation using the second chamber comprises: measuring, with a thirdlevel gage, a second interface between the water and the oil on thewaterside of the respective weir plate of the second chamber; andmeasuring, with a fourth level gage, the condensate on thecondensate-side of the respective weir plate of the second chamber. 11.The method of claim 10, wherein measuring with the third level gagecomprises measuring with a first magnetic level gage having a first lowlevel switch and a first level controller; and wherein performing thesecond operation comprises controlling a first level of the water withthe first level controller in operable communication with a first levelvalve in fluid communication with the respective water outlet of thesecond chamber; and wherein measuring with the fourth level gagecomprises a second magnetic level gage having a high level switch, asecond low level switch, and a second level controller; and whereinperforming the second operation comprises controlling a second level ofthe condensate with the second level controller in operablecommunication with a second level valve in fluid communication with therespective condensate outlet of the second chamber.
 12. The method ofclaim 1, wherein performing the first operation comprises measuring flowwith a first flow sensor in operable communication with the respectivecondensate outlet of the first chamber, a second flow sensor in operablecommunication with the respective gas outlet of the first chamber; and athird flow sensor in operable communication with the respective wateroutlet of the first chamber.
 13. The method of claim 1, furthercomprising measuring a temperature and a pressure in each of the firstand second chambers with a respective temperature gage and a respectivepressure gage in communication with each of the first and secondchambers.
 14. The method of claim 1, further comprising equalizing thefirst and second chambers across the barrier with an equalizing valve incommunication between the first and second chambers of the unitaryvessel.
 15. The method of claim 14, wherein equalizing the first andsecond chambers across the barrier comprises equalizing the first andsecond chambers across the barrier based on a pressure differentialbetween the respective inlets and outlets for the first and secondchambers.
 16. The method of claim 1, further comprising supporting theunitary vessel and integrated piping on a skid.
 17. The method of claim16, wherein connecting the outlet connections of the manifold to theintegrated piping of the unitary vessel comprises connecting to a firstconnection end disposed at one end of the skid for the respectivecondensate outlets of the first and second chambers combined, a secondconnection end disposed at the one end of the skid for the respectivewater outlets combined, and a third connection end disposed at the oneend of the skid for the respective gas outlets combined.
 18. The methodof claim 16, wherein connecting the inlet connections of the manifold tothe integrated piping of the unitary vessel comprises connecting to afirst connection end disposed at a side of the skid for the first inlet,and a second connection end disposed at the side of the skid for thesecond inlet.
 19. The method of claim 1, comprising welding a plate inthe interior of the unitary vessel, and sealing the first and secondchambers from one another with the welded plate as the barrier.
 20. Amethod for use with a manifold having inlet and outlet connections, themethod comprising: connecting the inlet connections of the manifold tointegrated piping of a unitary vessel, the unitary vessel defining aninterior, a barrier disposed in the interior of the unitary vesselsealing the interior into first and second chambers, the first chamberhaving a test inlet, the second chamber having a production inlet;connecting the outlet connections of the manifold to the integratedpiping of the unitary vessel, each of the first and second chambers incommunication with a respective gas outlet for gas, a respective wateroutlet for water, and a respective condensate outlet for condensate,each of the first and second chambers having a respective weir platedisposed in the respective chamber and separating the respective wateroutlet on a waterside of the respective weir plate from the respectivecondensate outlet on a condensate-side of the respective weir plate;isolating the second chamber and performing a well testing operationusing the first chamber; and isolating the first chamber and performinga production operation using the second chamber.